In Reply to: Continuous Casting of Brass posted by Greg Postma on 04/14/00 at 8:45 PM:
Continuous casting is done by pouring the metal into a cylindrical mold open at each end. As the metal solidifies, it is withdrawn from the cold end as hot metal continues to be poured in the hot end. The process produces a solid cylindrical bar which is then cut into the required lengths.
An extrusion, which forces a bar of metal through a die and produces a continuous formed bar, could, at best, give you projections on only 2 of the 4 sides and you would have to cut the continuous formed bar into the size you need.
Depending on the size of the protrusions, you may be able to form the parts by stamping.
Casting and forging are the best ways to produce near net shapes of unsymetrical parts - have you tried investment castings? The parts could easily be cast and the tooling costs are lower than most other processes.